Electrical and mechanical roof underlayment for solar shingles with air gap

ABSTRACT

Disclosed is a roofing underlayment providing mechanical and electrical connection for solar shingles that includes a water-impervious membrane adapted to be attached to a roof. The underlayment also includes a mechanical attachment member configured to mechanically attach a solar shingle to the roof, as well as an electrical conductor having an electrical first portion of which is embedded within the membrane, having an electrical second portion which is configured to electrically connect to a solar shingle, and having an electrical third portion which is configured to electrically connect to an electrical circuit. An air gap is provided that allows for air flow below the solar shingles. The air gap comprises a space between a bottom surface of the solar shingles and a bottom surface of the membrane.

TECHNICAL FIELD

This invention relates to roof systems with solar shingles.

BACKGROUND

Solar shingles have been available for more than a decade. Theinstallation of most of the solar shingle systems on the market todayare very labor intensive. With most systems, it is necessary to firstprepare the roof for the installation of the shingles. This may includeplacing a protective layer or water-resistant material on the roofsurface. Structural features may also be installed on the roof in orderto mechanically connect the shingles to the roof. These structuralfeatures may include some kind of rack or channel that the shinglesattach to. These racks or channels must be physically attached to theroof structure. Typically, this requires a penetration through thewater-resistant material and roof sheathing with screws or some otherattachment mechanism. Every penetration may create a potential forfuture leaks in the roof.

For traditional solar shingle systems, once the structure is in place tosupport the shingles, the electrical wiring must be provided to each ofthe shingles. Typically, each shingle is “daisy-chained” together withadjacent shingles in the same row, connecting a row of shingles inseries. At the end of each row there is normally a junction box thatcombines multiple rows of shingles and runs the combined power of thesemultiple rows of shingles to an electrical distribution system via anelectrical power panel in the house or building.

The connection of shingles to adjacent shingles is normally done byconnecting a shingle with an MC4 connector that provides a watertightelectrical connection between two adjacent shingles. The row wiring atthe end of each row of shingles typically has a junction box thatcombines multiple row wiring runs together, then has a combined home runback to the service panel.

Each step described in the foregoing requires a significant amount oflabor. Therefore, a system is needed to simplify:

-   -   1. The preparation of the roof surface to accommodate the        installation of the shingles.    -   2. The installation of the support structure (channels) for the        shingles.    -   3. The mechanical attachment of the shingles to a roof        structure.    -   4. The electrical connection of the shingles to each other.    -   5. The junction box connection of multiple shingle rows to each        other.    -   6. Installation of the “home run” from the j-box to the service        panel.

Many solar roof shingle systems typically consist of a series of solarshingles connected together either in series or in parallel. They arenormally connected by wires with male and female connectors on eitherside of the wiring that connects the shingles. The wiring is either runalong the backside of the shingles along a mounting rack, or along theinside of the back frame of the shingle itself. In some cases, thewiring is run inside a wiring chase or raceway behind the shingles.

In some cases, the shingles are applied directly to the roof surface. Inother cases, a support structure is attached to the roof that provides araceway for interconnecting wiring between the shingles. In every caseit is necessary to electrically connect each solar shingle to anelectrical circuit that distributes the electricity produced by thesolar shingles to an electrical circuit.

Alternatively, the connecting wiring for multiple shingles may beintegrated within the shingle itself, as described in patent applicationSer. No. 15/261,160 submitted 9 Sep. 2016, entitled “PhotovoltaicModular System”. When the wiring is integrated or embedded within eachof the shingles in the system, there still is the need to connect thewiring from the shingles to the electrical panel or devices being servedby the shingles. It is also necessary to structurally attach theshingles to the roof.

For many solar shingles, a junction box or other similar equipment,connectors or parts are required for the connection to the powercircuits that extend back to an electrical service panel. The connectionto the interconnecting wiring with wire nuts or connectors andinstalling junction boxes requires a lot of time and labor.

In addition to the electrical connections, there is also needed a systemto attach the shingles to a structure such as a roof structure. In somesystems, the shingles are attached to the roof with adhesive orotherwise physically attached by nails or screws.

It is known that many solar shingles that are attached directly to theroof surface are not as efficient because of heat buildup. Many of thetraditional systems do not provide a pathway for air to be transmittedbehind the shingles and out of the top ridgeline of the roof to allowfor naturally cooling of the shingles.

SUMMARY

In one aspect, the invention is roofing underlayment providingmechanical and electrical connection for solar shingles that includes awater-impervious membrane adapted to be attached to a roof. Theunderlayment also includes a mechanical attachment member configured tomechanically attach a solar shingle to the roof, as well as anelectrical conductor having an electrical first portion of which isembedded within the membrane, having an electrical second portion whichis configured to electrically connect to a solar shingle, and having anelectrical third portion which is configured to electrically connect toan electrical circuit. An air gap is provided that allows for air flowbelow the solar shingles. The air gap comprises a space between a bottomsurface of the solar shingles and a bottom surface of the membrane.

In another aspect, the invention is an electrical and mechanical roofunderlayment with an air gap which provides electrical and mechanicalconnection of solar shingles to a roof. An air gap is provided thatallows air flow to naturally cool the backside of the shingles toimprove energy production. The membrane simplifies the installation ofsolar shingles allowing the shingles to be installed and connectedtogether in the same step. The membrane has embedded electricalconductors and electrical connectors that provides an electricalconnecting system extending to an electrical circuit. The membranefurther has embedded mechanical members with mechanical connectors thatsecure the shingles to the membrane. The membrane is structurallyattached to a roof surface. The structural attachment may be an adhesiveattachment. Solar shingles are connected to the membrane by an integralclasping mechanism that mechanically and electrically connects theshingles to the membrane. No external wiring, connectors or devices arerequired to make the electrical connection between the shingles and themembrane. Contacts are integral and embedded into each individualshingle.

In a preferred embodiment, the electrical and mechanical roofunderlayment with air gap may provide electrical and mechanicalconnection of solar shingles to a roof. An air gap space between thesolar shingles and the membrane may be provided that allows air flow tonaturally cool the backside of the shingles to improve energyproduction. The membrane may simplify the installation of solar shinglesallowing the shingles to be installed and connected together in the samestep. The membrane may have embedded electrical conductors andelectrical connectors that provide an electrical connecting systemextending to an electrical circuit. The membrane may further haveembedded mechanical members with mechanical connectors that secure theshingles to the membrane. The membrane may be structurally attached to aroof surface. The structural attachment may be an adhesive attachment.Solar shingles may be connected to the membrane by an integral claspingmechanism that mechanically and electrically connects the shingles tothe membrane. No external wiring, connectors or devices may be requiredto make the electrical connection between the shingles and the membrane.Contacts may be integral and embedded into each individual shingle.

In summary, the key advantages posited for the Electrical and MechanicalRoof Underlayment with Air Gap include a system that:

provides an electrically insulated and environmentally protected pathwayfrom the solar shingles to the electrical devices being served or to anelectrical service panel;

provides a protected connection between the shingles and the electricalconductors and wiring connecting the shingles to electrical loads orpanel;

provides a mechanical connection of the shingles to the membrane;

provides a structural attachment of the membrane to the roof structure;

allows multiple shingles or rows of interconnected shingles to beconnected to this electrical interconnection system;

Provides an air gap between the shingles and the membrane for air flow;

simplifies installation by providing a peel and stick adhesive systemthat allows the attachment of the membrane to a roof or other buildingstructure; and

further simplifies the installation by making the electrical connectionof the shingles to the electrical interconnection system by a simpleplug-in connection.

Features and advantages of different embodiments of the invention willbecome more fully apparent from the following description and appendedclaims or may be learned by practice of the invention as set forthhereinafter.

Consistent with the foregoing, a roofing underlayment with air gapproviding mechanical and electrical connection for solar shingles isdisclosed. The objectives of the system are to provide an electrical andmechanical roof membrane which provides electrical and mechanicalconnection of solar shingles to a roof. The membrane has embeddedelectrical conductors and electrical connectors that provides anelectrical connecting system extending to an electrical circuit. Themembrane further includes embedded mechanical members with mechanicalconnectors that secure the shingles to the membrane. The membrane isstructurally attached to a roof surface. The structural attachment maybe an adhesive attachment. Solar shingles are connected to the membraneby an integral clasping mechanism that mechanically and electricallyconnects the shingles to the membrane. No external wiring, connectors ordevices are required to make the electrical connection between theshingles and the membrane. Contacts are integral and embedded into eachindividual shingle. Additional objectives include simplifying theinstallation of solar shingles allowing the shingles to be installed andconnected together in the same step.

In a preferred embodiment, a roofing underlayment with air gap providingmechanical and electrical connection for solar shingles may include awater-impervious membrane adapted to be attached to a roof. The membranemay also include a mechanical attachment member having a mechanicalfirst portion embedded within the membrane and having a mechanicalsecond portion extending above the membrane. The mechanical secondportion of the mechanical attachment member may be configured tomechanically attach a solar shingle to the roof. The membrane may alsoinclude an electrical conductor having an electrical first portion ofwhich is embedded within the membrane, having an electrical secondportion which is configured to electrically connect to a solar shingle,and having an electrical third portion which is configured toelectrically connect to an electrical circuit. An air gap that allowsfor air flow below the solar shingles may also be included. The air gapmay be an space between a bottom surface of the solar shingles and abottom surface of the membrane.

In another embodiment, the mechanical attachment member may runsubstantially the length of the membrane and have multiple portionsembedded within the membrane and multiple portions extending above themembrane for attaching multiple solar shingles. The multiple portionsextending above the membrane may be mechanically configured forreceiving attachment members on multiple solar shingles. The attachmentmembers on the multiple solar shingles may also include electricalconnection features.

In an embodiment, the electrical conductor may have multiple electricalportions configured to electrically connect multiple solar shingles.

In one embodiment, the membrane may also include a second mechanicalattachment member that runs substantially the length of the membrane andparallel to the mechanical attachment member and at least a secondelectrical conductor that runs parallel to the electrical conductor.

In a certain embodiment, the mechanical second portion of the mechanicalattachment member and the electrical second portion of the electricalconductor may be in proximity and configured so that mechanicalattachment and electrical connection of the solar shingle happensimultaneously. In an embodiment, the electrical third portion of theelectrical conductor may include an insulated cable with a plug-inelectrical connector for connecting to the electrical circuit. Theelectrical third portion of the electrical conductor may include asecond plug-in electrical connector for connecting to the electricalsecond portion of the electrical conductor.

In an embodiment, the membrane may be adapted to be attached to a roofby adhesive. The adhesive may be a pressure-sensitive adhesive protectedby a peelable layer prior to attachment to the roof. In anotherembodiment, the membrane may also include a raised area for connectingthe multiple electrical portions to the multiple solar shingles.

In certain embodiments, a membrane may include a water-imperviousmembrane adapted to be attached to a roof by adhesive, and may include amechanical attachment member running substantially the length of themembrane and have multiple alternating embedded portions within themembrane and extending portions extending above the membrane, whereinthe extending portions each are mechanically configured for attaching asolar shingle to the roof. The membrane may also include an electricalconductor running substantially the length of the membrane and having atleast a first embedded portion embedded within the membrane, havingmultiple connecting portions extending above the membrane configured toelectrically connect to each of the solar shingles, and having a thirdportion configured to plug in and electrically connect to an electricalcircuit. In an embodiment, the connection portions and the electricalextending portions may be positioned and configured so that solarshingles are mechanically attached and electrically connectedsimultaneously and without creating holes through the membrane. An airgap that allows for air flow below the solar shingles may also beincluded. The air gap may be a space between a bottom surface of thesolar shingles and a bottom surface of the membrane.

In one embodiment, the membrane may include at least a second mechanicalattachment member of similar construction and running parallel to themechanical attachment member and at least a second electrical conductorof similar construction and running parallel to the electricalconductor. The electrical conductor may have multiple electricalportions configured to electrically connect multiple solar shingles. Themultiple portions extending above the membrane may be mechanicallyconfigured for receiving attachment members on multiple solar shingles.The attachment members on the multiple solar shingles may also includeelectrical connection features.

In certain embodiments, the mechanical attachment member and themultiple electrical portions of the electrical conductor may be inproximity and configured so that mechanical attachment and electricalconnection of the solar shingle happen simultaneously. The membrane maybe adapted to be attached to a roof by adhesive. The membrane mayfurther include a raised area for connecting the multiple electricalextending portions to the multiple solar shingles.

Further aspects and embodiments are provided in the foregoing drawings,detailed description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are provided to illustrate certain embodimentsdescribed herein. The drawings are merely illustrative and are notintended to limit the scope of claimed inventions and are not intendedto show every potential feature or embodiment of the claimed inventions.The drawings are not necessarily drawn to scale; in some instances,certain elements of the drawing may be enlarged with respect to otherelements of the drawing for purposes of illustration.

FIG. 1A is an isometric view of the underlayment.

FIG. 1B is a section view from an end view vantage point of a membrane.

FIG. 1C is a section view from a side view vantage point of a membrane.

FIG. 1D is an isometric view of a roof with vertical membranes installedon the surface of a roof.

FIG. 1E is an isometric view of a roof with horizontal membranesinstalled on the surface of a roof.

FIG. 2A is a top view of three membranes connected together.

FIG. 2B is a section view of three membranes connected together.

FIG. 3 is an illustration of a membrane with three shingles beinginstalled in order.

FIG. 4 is an illustration of several shingles connected together on topof a membrane.

FIG. 5 is a section view of a membrane on a roof surface with a shingleon top of the membrane.

FIG. 6 is an isometric view of a membrane with piping.

FIG. 7 is an isometric view of a building with the air flow version ofthe membrane installed on a roof.

FIG. 8 is a section view of the corrugated airflow membrane (CAM).

FIG. 9B is a section view of the CAM showing exterior portions alongwith embedded sections of the structural member.

FIG. 9C is a section view of a second embodiment of the CAM showingexterior portions along with embedded sections of the structural member.

FIG. 10A is a section view of the structural loop exterior portion withclasping mechanism and electrical contacts.

FIG. 10B is an overhead view of a shingle aligning with a membrane.

FIG. 11A is a cross section view of membrane.

FIG. 11B is an overhead view of a mechanical/electrical connector withconnections to the embedded electrical conductor.

FIG. 12A is a side section view of mechanical/electrical connectorinside a membrane with solar shingles connected to the membrane.

FIG. 12B is a side section view of another embodiment of amechanical/electrical connector.

FIG. 13A is a side view section of multiple solar shingles attached tothe membrane with an air gap between the shingles and the membrane.

FIG. 13B is an overhead view of two shingles with connectors.

FIG. 13C is a perspective drawing of a mechanical/electrical connector.

DETAILED DESCRIPTION

The following description recites various aspects and embodiments of theinventions disclosed herein. No particular embodiment is intended todefine the scope of the invention. Rather, the embodiments providenon-limiting examples of various compositions, and methods that areincluded within the scope of the claimed inventions. The description isto be read from the perspective of one of ordinary skill in the art.Therefore, information that is well known to the ordinarily skilledartisan is not necessarily included.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment. Thus, appearances of the phrases“in one embodiment,” “in an embodiment,” and similar language throughoutthis specification may, but do not necessarily, all refer to the sameembodiment, but mean “one or more but not all embodiments” unlessexpressly specified otherwise. The terms “including,” “comprising,”“having,” and variations thereof mean “including but not limited to”unless expressly specified otherwise. An enumerated listing of itemsdoes not imply that any or all of the items are mutually exclusiveand/or mutually inclusive, unless expressly specified otherwise. Theterms “a,” “an,” and “the” also refer to “one or more” unless expresslyspecified otherwise.

Definitions

The following terms and phrases have the meanings indicated below,unless otherwise provided herein. This disclosure may employ other termsand phrases not expressly defined herein. Such other terms and phrasesshall have the meanings that they would possess within the context ofthis disclosure to those of ordinary skill in the art. In someinstances, a term or phrase may be defined in the singular or plural. Insuch instances, it is understood that any term in the singular mayinclude its plural counterpart and vice versa, unless expresslyindicated to the contrary.

As used herein, the singular forms “a,” “an,” and “the” include pluralreferents unless the context clearly dictates otherwise. For example,reference to “a substituent” encompasses a single substituent as well astwo or more substituents, and the like.

As used herein, “for example,” “for instance,” “such as,” or “including”are meant to introduce examples that further clarify more generalsubject matter. Unless otherwise expressly indicated, such examples areprovided only as an aid for understanding embodiments illustrated in thepresent disclosure and are not meant to be limiting in any fashion. Nordo these phrases indicate any kind of preference for the disclosedembodiment.

“Solar shingles” and “shingles” as referred to throughout this documentmay refer to an electrical module that produces energy, collects energy,produces power, transmits power, conducts electricity, communicatesenergy, converts energy from one form to another, and combinations ofone or more of the foregoing. “Solar Shingles” in a preferredembodiment, also refer to Photovoltaic (PV) electrical modules thatcollect solar energy from the sun and convert it to electrical energy.In a preferred embodiment, the solar shingles also provide protectionfrom the environment (wind, rain and other wind-blown materials or otherelements), in that they act as actual roof shingles.

The six steps listed above for a traditional system are repeated herefor reference:

-   -   1. The preparation of the roof surface to accommodate the        installation of the shingles.    -   2. The installation of the support structure (channels) for the        shingles.    -   3. The mechanical attachment of the shingles to a roof        structure.    -   4. The electrical connection of the shingles to each other.    -   5. The junction box connection of multiple shingle rows to each        other.    -   6. Installation of the “home run” from the j-box to the service        panel.

The electrical and mechanical roof underlayment with air gap describedherein simplifies each one of these steps and provides an efficientmethod and system for installing solar shingles on a roof. Rather thansix steps, there are essentially only three steps involved:

-   -   1. Install (peel and stick) the membrane on the roof surface.    -   2. Install (plug in) the shingles to the membrane.    -   3. Install the home run to the service panel.

The membrane itself provides a solution to the first four steps listedfor the traditional solar shingle systems. The membrane is adhesivelyattached to the roof and has all of the mechanical and electricalconnection features embedded in the membrane. This allows the supportstructure for the shingles to be easily applied to the surface of theroof without any penetrations, thus eliminating any potential for leaksor water intrusion at the attachment point. The mechanical andstructural forces required to attach the shingles to the roof are spreadout over a wide area by incorporating the structural and mechanicalmembers inside the membrane itself.

Once the membrane is installed on the roof, each shingle is simply“plugged in” to the mechanical and electrical connections on themembrane. In a preferred embodiment, the connectors the shingle isplugged into have a combined mechanical/electrical connector that makethe mechanical and electrical connections to each shingle at the sametime in one step. In other words, each shingle is simply plugged in tothe membrane and both connections are made simultaneously. This greatlyreduces the amount of labor normally needed to make two separateconnections. It also eliminates the need for tools to physically attachthe shingle to the support structure. The shingle connectors areintegrated onto the shingle itself along the edge of the shingle and arecombined mechanical/electrical connectors in a preferred embodiment.

The membrane connector is shaped with a large opening at the entrance tothe connector to allow the shingle to be slightly misaligned at thepoint of entry. The opening of the connector narrows and necks down to anarrower opening as the shingle slides into place. This funnel typeshape or tapered configuration further simplifies the installation byproviding a structure that enables the connection of the connector tohandle a typical slightly misaligned entry of the shingle into theconnector.

The membrane has an array of connectors configured as needed for thelayout of the shingles on the roof. The electrical and mechanicalsupport members are partially embedded inside the membrane, with aportion of the members extending above the top surface of the membraneforming a connector. Each shingle is plugged into at least two of theseconnectors to attach it to the membrane. Refer to the following figuresfor a more detailed description of the invention.

Figures

FIG. 1A is an isometric view of the underlayment. The membrane 110 shownin the illustration has a top surface 116 that interfaces with a bottomsurface of an adjacent membrane (not shown). The bottom surface 114 ofthe membrane 110 interfaces with another adjacent membrane (not shown).Thus, multiple membranes may be connected together. In some embodimentsmultiple membranes are adhesively connected. The tapered interface ofsurface 116 and surface 114 are thinner than the main body of themembrane allowing the membrane 110 to have the same thickness across theentire area of membrane coverage.

In certain embodiments, membrane 110 further comprises a raised area 140that includes electrical contacts 134 and 136 on the exterior of themembrane 110 top surface as shown. In the embodiment shown in FIG. 1A,the raised area 140 allows water and other environmental elements suchas dust, dirt and debris to be washed away from the electrical contactarea and down off of the roof. This allows contacts 134 and 136 to havean exposed contact area flush with the surface of membrane 110,simplifying electrical connections to contacts 134 and 136.

Insulated electrical conductors 130 and 132 may be comprised of one ormore of electrically conductive materials including alloys of copper,aluminum, nickel, stainless steel, silver, graphite, tungsten, carbideor combinations thereof. In an embodiment, the conductors may be abusway or bulbar rather than electrical wiring. The conductors 130 and132 may also be flexible. Electrical wires 102 are connected toconductors 130 and 132 and extend outside of membrane 110 to anelectrical circuit. The electrical circuit may be inside a buildingcovered by a roof structure.

Partially embedded structural member 124 as shown in FIG. 1A includes anembedded portion 122 along with an exterior portion 120 that iscompletely outside of the membrane. In certain embodiments, the exteriorportion 120 of the structural member 124 forms a loop that allows themechanical connection of a shingle to the membrane 110.

FIG. 1B is a section view from an end view vantage point of membrane110. Tapered top surface 116 and bottom tapered surface 114 are shown.In certain embodiments, both of these surfaces may have adhesive placedon the surface to allow multiple membranes to be adhesively connectedtogether. Adhesive 142 may be placed on the entire bottom surface ofmembrane 110 and have a protective backing material 144 that is removedat a time of installation, exposing the adhesive 142. In otherembodiments the adhesive 142 may cover portions of one or more surfacesof the membrane 110.

In the embodiment shown, raised area 140 may include both electricalcontacts 134 and 136 along with structural embedded portion 122. Inother embodiments the raised area 140 may include only electricalcontacts 134 and 136 and the embedded portion may be at a lower levelnot included in the raised area. Exterior portion 120 of the structuralmember is also shown in this embodiment. Electrical conductors 104 and106 are shown connecting insulated electrical conductors 130 and 132 toelectrical contacts 134 and 136.

FIG. 1C is a section view from a side view vantage point of membrane110. This embodiment illustrates how partially embedded structuralmember 124 forms a loop 126 on the exterior portion 120 of thestructural member 124. Structural embedded portion 122 is also showncompletely embedded inside the membrane 110.

FIG. 1D is an isometric view of a roof with vertical membranes installedon the surface of roof 150. Three membranes 152, 154 and 156 areinstalled on the roof 150 surface as shown. In this embodiment, each ofthe three membranes 152, 154 and 156 are placed on roof 150 running fromtop ridge 143 and extending down to a bottom edge near the soffit, raingutter or drip edge. The exterior portion 120 of the structural memberis shown exposed on the top surface of the membrane. Insulatedelectrical conductors 130 are shown running parallel within eachmembrane. In this embodiment, membranes 152, 154 and 156 areelectrically connected to membrane conductors 145 that run parallel withthe roof ridge 143. Electrical wiring 149 extends from the membraneconductors 145 to electrical junction box 147 in attic. Wiring 160extends this circuit to an electrical circuit inside a building belowthe roof.

FIG. 1E is an isometric view of a roof with horizontal membranesinstalled on the surface of roof 150. Three membranes 152, 154 and 156are installed on the roof 150 surface as shown. In this embodiment, eachof the three membranes 172, 174 and 176 are placed on roof 150 runningparallel to the top ridge and parallel to the roof drip edge. Theexterior portion 120 of the structural member is shown exposed on thetop surface of the membrane. Insulated electrical conductors 130 areshown running parallel within each membrane. In this embodiment,membranes 172, 174 and 176 are electrically connected to membraneconductors 164 that run perpendicular to membranes 172, 174 and 176.Electrical wiring 168 extends from the membrane conductors 164 toelectrical junction box 147 in attic. Wiring 160 extends this circuit toan electrical circuit inside a building below the roof.

FIG. 2A is a top view of three membranes connected together. In order toprovide support for the installation of solar shingles over an entireroof area, multiple membranes may be placed in multiple rows (eitherhorizontally as shown in FIG. 1E or vertically in FIG. 1D) as needed tocover a larger area. In this embodiment, three parallel membranes 216,218 and 220 are shown connected together. Overlap area 207 shows how theright edge of membrane 216 overlaps the left edge of membrane 218, forexample. Insulated electrical conductors 130 and 132 are shown embeddedwithin each membrane.

In this embodiment, embedded portion 122 along with exterior portion 120are shown running parallel with each membrane. In certain embodiments,the membrane is semi-flexible and may be rolled-up prior toinstallation. The membrane may then be un-rolled at the time ofinstallation. In this embodiment, the structural member may run parallelto the direction of the long length of membrane material so that it canbe rolled up and un-rolled for installation as required. Each membranemay be adhesively attached to the roof surface in turn. For example,membrane 220 may be installed first and be adhesively attached to a roofsurface. After that, membrane 218 may then be adhesively attached to theroof with overlap area 207 of membrane 218 being adhesively attached tomembrane 220 forming a seal between the two membranes. Top surface 116and bottom surface 114 may interface with adjacent membranes if needed.

As shown in this embodiment, membranes 216, 218 and 220 are runningvertically with the roof similar to what is illustrated in FIG. 1D. Inthis example embodiment, each of the membranes 216, 218 and 220 have acenter section 205 that is depressed and lower than the main body of themembrane to allow for water flow. This allows for rain water to shedtowards this trough area and away from the main surface area of eachmembrane. This also may encourage debris and dust to be washed down andaway from the membrane by rain water. Overlap area 207 is alsoconfigured as a trough which is lower than the rest of the membrane.

FIG. 2B is a section view of three membranes connected together. In thisembodiment, three membranes 216, 218 and 220 are shown connectedtogether. Overlap area 207 shows how the right edge of membrane 216overlaps the left edge of membrane 218, for example. Insulatedelectrical conductors 130 and 132 are shown embedded within eachmembrane. Raised area 140 is also shown. Embedded portion 122 along withexterior portion 120 are shown

In this embodiment, membrane 220 may be installed first and beadhesively attached to a roof surface. After that, membrane 218 may thenbe adhesively attached to the roof with overlap area 207 of membrane 218being adhesively attached to membrane 220 forming a seal between the twomembranes. Top surface 116 and bottom surface 114 may interface withadjacent membranes. Each of the membranes 216, 218 and 220 may have acenter section 205 that is depressed and lower than the main body of themembrane to allow for water flow. Overlap area 207 is also configured asa trough which is lower than the rest of the membrane.

FIG. 3 is an illustration of a membrane with three shingles beinginstalled in order. Membrane 110 is shown with structural loops 340ready to receive the insertion of shingles 310, 312 and 314. Shingle 310and 312 are demonstrating how they are approaching membrane 110 duringinstallation. Mechanical connection clasps 320 are ready to engage withloops 340 as they are approaching connection. Loops 340 are wedge shapedto allow clasps 320 to align with the insertion point as needed. Shingle314 is fully inserted and the clasps 328 are fully engaged with theloops. Clasps 328 may have a mechanism that locks shingle 314 into placeonce fully inserted. Clasp 328 may also have a mechanical release thatallows for shingle 314 to be removed if needed in the future. In somecases, one or more shingles may receive damage or otherwise may need tobe replaced. A releasing mechanism may allow a shingle to be removed andreplaced with a new shingle. In other embodiments, a clasping andrelease mechanism may reside on the structural loop 340 allowingshingles to be connected. In this example, a loop or similar structuralcomponent may be located on the shingle allowing connection to a claspon the membrane structure.

FIG. 4 is an illustration of several shingles connected together on topof a membrane. Shingle 410 is mechanically connected to structural loops430 at the top and structural loops 432 at the bottom of the shingle410. Shingle 412 is connected with structural loops 434 at the bottom ofshingle 412. Structural loop 432 and loop 434 also connect to shingle416. In this way, each structural loop may engage with more than oneshingle. Each shingle may have a mechanical clasp that allows more thanone shingle to attach to a single loop. Adjacent shingles may alsooverlap with structural loops holding them in the proper overlappingposition as required. Shingle 416 shares connections 436 with shingles420 and 422. Shingle 420 has shared connections to loop 440, loop 436and loops 446. Shingle 422 has shared connections with loop 436, loop442 and loops 448.

FIG. 5 is a section view of a membrane on a roof surface with a shingleon top of the membrane. Membrane 110 has piping embedded inside themembrane to allow for air flow through the membrane. This airflow keepsthe shingles cool by allowing fresh air to be drawn in from the loweredge of the membrane and commuted upwards towards the ridgeline wherethe hot air may be vented out of vents along the ridgeline. Pipes 512are inside the membrane 110 as shown. Airflow may enter the inside space516 of the piping as required. Air may also enter the space 514 betweenpiping 512.

In certain embodiments, solar cells 540 may be embedded in electricalshingle 510. Electrical shingle 510 may be a solar shingle in anembodiment. Airflow below the solar shingle may enhance the performanceof the solar cells by keeping the backside of the solar cells 540cooler. Structural loop exterior portions 120 are also shown whichsecure the shingle 510 to the membrane 110. Membrane 110 is structurallyconnected to roof structure 520. The membrane 110 may be adhesivelyattached to the roof surface. In other embodiments, the membrane may bestructurally attached by other connection systems such as screws, clips,clasps, tracks, grooves or other structural means.

FIG. 6 is an isometric view of a membrane with piping. Pipes 512 runfrom the lower edge of the membrane 110 near the drip edge of a roof uptowards the ridgeline of the roof. Airflow 620 enters the lower end ofpiping 512 at the bottom opening of the pipes 512 and the air istransmitted by natural heat convection up and out the top opening ofpiping 512. Heated air 622 is vented out of the piping 512, and space514 between the piping 512 to the outside air via venting along theupper ridgeline of a roof. Structural loop exterior portions 120 arealso shown.

In some cases, wind may create an uplift at the lower edge of membrane110, causing uplift and potentially causing damage to the membrane 110or even possibly removing the entire membrane (or sections of it) fromthe roof. To prevent this uplift, the top layer of the membrane 110 maybe configured with a shielding 610 at the lower edge of membrane 110near the rain gutter and drip edge. In this way, the open ends of thepiping 512 along with the space 514 between piping 512 may be protectedfrom direct air flow from the wind. The shielding may be configured toeither redirect the airflow or disturb and dissipate the energy of theairflow to reduce the velocity of the flow into the space under theshingles.

FIG. 7 is an isometric view of a building 705 with the air flow versionof the membrane installed on the roof 150. Cool air 722 is drawn in atthe lower edge of membrane 110 and drawn up through the piping 512 tothe top ridge 708 and the now heated air 720 is vented out throughventing along the ridgeline 708. Wind shielding 610 is also shown. Acorrugated airflow membrane (CAM) 710 is also shown. The shape of theCAM 710 also creates channels for the airflow to transmit up from thebottom edge 712 of the CAM 710, up through the membrane 710 and to theridgeline 708 venting above.

FIG. 8 is a section view of the corrugated airflow membrane (CAM). CAM710 is shown with shingle 810 mounted to the top of the CAM 710. The CAM710 is also structurally attached to roof sheeting 822 which is in turnstructurally attached to roof structure 820.

FIG. 9A is an isometric view of the CAM 710. Structural loop exteriorportions 120 are also shown. In this embodiment, the membrane itself isstructured in a corrugated shape in order to allow for airflow above andbelow each section of the CAM 710.

FIG. 9B is a section view of the CAM 710 showing Structural loopexterior portions 120 along with embedded sections 122 of the structuralmember. shingles 910 are also shown. In this example embodiment,insulated electrical conductors 920 are conformally attached to thebottom surface of the CAM 710.

FIG. 9C is a section view of a second embodiment of the CAM 710 showingStructural loop exterior portions 120 along with embedded sections 122of the structural member. Shingles 910 are also shown. In this exampleembodiment, insulated electrical conductors 922 are embedded inside ofthe CAM 710.

FIG. 10A is a section view of the structural loop exterior portion 120with clasping mechanism and electrical contacts. In this embodiment, theelectrical contacts 1020 and 1030 are embedded in the clasping mechanism320 of a shingle. Electrical connections are made between shinglecontact 1030 and membrane contact 1032. Likewise, shingle contact 1020makes an electrical connection with membrane contact 1022. Electricalwire 1034 connects membrane contact 1032 to insulated electricalconductor 130. Electrical wire 1024 connects membrane contact 1022 toinsulated electrical conductor 132. This embodiment demonstrates how theelectrical connections may be incorporated within the claspingmechanism. The electrical connections may also be within the structuralloop.

FIG. 10B is an overhead view of a shingle 1010 aligning with membrane110. The structural loop exterior portion 120 is shown on top ofmembrane 110. In this embodiment, the electrical contacts 1020 and 1030are embedded in the clasping mechanism 320 of a shingle.

Shingle contact 1030 aligns with membrane contact 1032. Likewise,shingle contact 1020 aligns with membrane contact 1022. Electrical wire1034 connects membrane contact 1032 to insulated electrical conductor130. Electrical wire 1024 connects membrane contact 1022 to insulatedelectrical conductor 132.

FIG. 11A is a cross section view of membrane 110. The structural loopexterior portion 120 and embedded portion 122 is shown. In thisembodiment, the membrane contacts 134 and 136 are embedded in themembrane 110 below exterior portion 120 of shingle 110. Electrical wire1034 connects membrane contact 1032 to insulated electrical conductor130. Electrical wire 1024 connects membrane contact 1022 to insulatedelectrical conductor 132. Raised area 140 is at a higher level than therest of the membrane providing a “high point” for water and othermaterial from entering the electrical connection point of the connector.The raised area 140 sheds water away from the contacts 134 and 136.

FIG. 11B is an overhead view of a mechanical/electrical connector withconnections to the embedded electrical conductor. Electrical contacts134 and 136 are shown below exterior portion 120. Embedded electricalconductors 130 and 132 are electrically connected to connectorelectrical contacts 134 and 136 via interconnecting wiring 104 and 106.

FIG. 12A is a side section view of mechanical/electrical connectorinside a membrane with solar shingles connected to the membrane. FirstShingle 1210 has electrical contacts 1245 and 1247 embedded along theedge of the first shingle 1210. Contacts 1245 and 1247 electricallyconnect to membrane contacts 134 and 136. Contacts 134 and 136 areelectrically connected to electrical conductors 130 and 132 as shown.Second shingle 1260 is mechanically attached to membrane 110 viamechanical exterior portion 120. Bottom lip 1232 of second shingle 1260mechanically holds the second shingle 1260 in place by sliding in underexterior portion 120. Upper lip 1220 of second shingle 1210 overlaps topsection 1230 of first shingle 1210 allowing water to run off and notenter the connection area below. Waterproof seal 1298 may also beprovided, preventing water from entering the electrical connectionbelow. Embedded portion 122 is also shown. Raised area 140 as shown inthis example is raised and at a level higher than both attachedshingles. Embedded electrical conductors 130 and 132 are electricallyconnected to connector electrical contacts 134 and 136.

FIG. 12B is a side section view of another embodiment of amechanical/electrical connector. In this example, first shingle 1280sits on top of membrane 110. Second shingle 1270 has an overlap section1272 that lays on top of first shingle 1280 providing both mechanicalsupport to hold first shingle 1280 in place and also provides awaterproof seal 1298 preventing water from entering the electricalconnection below. Second shingle 1270 is mechanically attached tomembrane 110 via lower lip 1274 inserted into mechanical exteriorportion 120. Electrical contacts 1282 and 1284 are embedded in secondshingle 1270 and electrically connect to membrane contacts 1286 and1288. Waterproof seal 1290 may also be provided to prevent waterpenetration into the electrical connection area. Watertight seal gasketallowance features 1292 may also be provided to allow for a tightconnection of the waterproof seal 1290 between the second shingle 1270and the membrane 120. Embedded portion 122 is also shown.

FIG. 13A is a side view section of multiple solar shingles attached tothe membrane with an air gap between the shingles and the membrane.Shingles 1320 are held in place by mechanical/electrical connectors1310. Air flow 1330 is shown passing through each connector 1310 andbetween the air gap 1350 between the shingles 1320 and the membrane 110.Embedded portion 1340 of connector 1310 is also shown.

FIG. 13B is an overhead view of two shingles with connectors. Connectors1310 are shown at the exterior corners of shingles 1320. Middleconnectors 1312 are shown which provide additional mechanical andelectrical redundancy in case of any failure to the connectors 1310. Airflow 1330 is shown passing under the solar shingles 1320. Air flow belowthe shingles allows the shingles to perform at their highest efficiency.It is known that the cooler the back of the shingles, the more efficientthe power output of the shingles.

FIG. 13C is a perspective drawing of a mechanical/electrical connector.Membrane 110 is shown with mechanical/electrical connector 1310,exterior portion 1342 and embedded portion 1340. Air holes 1380 may beprovided in the connector 1310 to allow air flow 1330 through theconnector 1310.

The described embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

All patents and published patent applications referred to herein areincorporated herein by reference. The invention has been described withreference to various specific and preferred embodiments and techniques.Nevertheless, it is understood that many variations and modificationsmay be made while remaining within the spirit and scope of theinvention.

What is claimed is:
 1. A roofing underlayment providing mechanical andelectrical connection for solar shingles comprising: a water-imperviousmembrane adapted to be attached to a roof; a mechanical attachmentmember configured to mechanically attach a solar shingle to the roof;and an electrical conductor having an electrical first portion of whichis embedded within the membrane, having an electrical second portionwhich is configured to electrically connect to a solar shingle, andhaving an electrical third portion which is configured to electricallyconnect to an electrical circuit; and an air gap that allows for airflow below the solar shingles, wherein the air gap comprises a spacebetween a bottom surface of the solar shingles and a bottom surface ofthe membrane.
 2. The invention of claim 1, wherein the membrane has acorrugated shape creating the air gap.
 3. The invention of claim 1,wherein the air gap comprises channels that run from one side of themembrane to an opposite side.
 4. The invention of claim 1, wherein thechannels comprise pipes.
 5. The invention of claim 1, wherein themechanical attachment members hold the shingles a distance above a topsurface of the membrane, thus creating the air gap.
 6. The invention ofclaim 1 wherein the mechanical attachment member runs substantially thelength of the membrane and has multiple portions embedded within themembrane and multiple portions extending above the membrane forattaching multiple solar shingles.
 7. The invention of claim 6comprising at least a second mechanical attachment member that runssubstantially the length of the membrane and parallel to the mechanicalattachment member and at least a second electrical conductor that runsparallel to the electrical conductor.
 8. The invention of claim 5wherein the electrical conductor has multiple electrical portionsconfigured to electrically connect multiple solar shingles.
 9. Theinvention of claim 1, wherein the electrical third portion of theelectrical conductor comprises an insulated cable with a plug-inelectrical connector for connecting to the electrical circuit.
 10. Theinvention of claim 8 wherein the electrical third portion of theelectrical conductor comprises a second plug-in electrical connector forconnecting to the electrical second portion of the electrical conductor.11. The invention of claim 1 wherein the membrane is adapted to beattached to a roof by adhesive.
 12. The invention of claim 11 whereinthe adhesive is a pressure-sensitive adhesive protected by a peelablelayer prior to attachment to the roof.
 13. A roofing underlaymentproviding mechanical and electrical connection for solar shinglescomprising: a water-impervious membrane adapted to be attached to a roofby adhesive; a mechanical attachment member running substantially thelength of the membrane and have multiple alternating embedded portionswithin the membrane and extending portions extending above the membrane,wherein the extending portions each are mechanically configured forattaching a solar shingle to the roof; an electrical conductor runningsubstantially the length of the membrane and having at least a firstembedded portion embedded within the membrane, having multipleconnecting portions extending above the membrane configured toelectrically connect to each of the solar shingles, and having a thirdportion configured to plug in and electrically connect to an electricalcircuit; wherein the connection portions and the electrical extendingportions are positioned and configured so that solar shingles aremechanically attached and electrically connected simultaneously andwithout creating holes through the membrane; and an air gap that allowsfor air flow below the solar shingles, wherein the air gap comprises aspace between a bottom surface of the solar shingles and a bottomsurface of the membrane.
 14. The invention of claim 13, wherein themembrane has a corrugated shape creating the air gap.
 15. The inventionof claim 13, wherein the air gap comprises channels that run from oneside of the membrane to an opposite side.
 16. The invention of claim 13,wherein the channels comprise pipes.
 17. The invention of claim 13,wherein the mechanical attachment members hold the shingles a distanceabove a top surface of the membrane, thus creating the air gap.
 18. Theinvention of claim 13 further comprising at least a second mechanicalattachment member of similar construction and running parallel to themechanical attachment member and at least a second electrical conductorof similar construction and running parallel to the electricalconductor.
 19. The invention of claim 13 wherein the multiple portionsextending above the membrane are mechanically configured for receivingattachment members on multiple solar shingles.
 20. The invention ofclaim 13 wherein the membrane is adapted to be attached to a roof byadhesive.